Plant Manager - Lean Manufacturing

SUMMARY OF QUALIFICATIONS

A proven leader with ** years of management experience in a manufacturing facility, a degree in Industrial Engineering and a passion for continuous improvement/lean manufacturing. This experience and education has led to outstanding results in financial performance, delivery, quality and safety.

PROFESSIONAL EXPERIENCE

Meridian Automotive Systems

Plant Manager - Grabill, Indiana 2006 – Present

Responsibilities and Accomplishments

• Full P&L and balance sheet responsibility for a class A SMC molding and top coating facility with $27M in

annualrevenue.

• Successfully directed 200 direct and 60 indirect associates in our three shift operation.

• Implemented annual cost saving projects of $4.5M in 2008.

• Reduced Direct Labor dollars as % of sales by 50% utilizing lean manufacturing principles.

• Reduced purchased/raw material inventory by 31% by implementing a lean materials market.

• Initiated a “Green Team” which generated annual utility and overhead savings of $366K in 2008.

• Reduced the plants OHSA Recordable injury rate from 8.5 to 6.8.

• Improved on-time delivery from 93.4% to 99.8%.

• Reduced quality defects by 16% while reducing quality auditor positions from 18 to 1.

• Led the implementation of the Toyota Production System. Implementation included Value Stream Mapping,

Standardized Work, One Piece Flow, Pull Systems, 5S and TPM.

• Maintained TS96949 and ISO 14001 certifications.

Operations Manager - Grabill, Indiana 2005 –2006

Responsibilities and Accomplishments

• Responsible for 5 supervisors and more than 190 direct employees in the SMC Molding, bonding, prime and

top coat paint lines.

• Facilitated and lead 7 Kaizen events with hourly associates. As a result, direct labor as a % of sales was

reduced from 26% to 19% (equivalent to $1.5M annual savings). These events were used to heighten awareness

and train the hourly work force on lean principles as well as reduce cost.

• Integral part of the team that improved 2006 EBITDA by more than 40% year over year.

• Initiated lean changes beginning with 5S and plant organization. Implemented a 5S scorecard to measure

plant performance.

• Developed a plan to design and implement Standardized work for all manufacturing processes.

Materials Manager - Salisbury, North Carolina 2003 – 2005

Responsibilities and Accomplishments

• Managed 20 associates while overseeing the following areas: scheduling, shipping, receiving and ordering of

direct and indirect materials.

• Reduced service order backlog for all major customers by over 90% from previous year.

• Reduced premium freight by 55% year over year.

• Facilitated various lean manufacturing continuous improvement events resulting in annual savings of over $1.1M.

• Implemented Mapics Inventory and Scheduling modules.

• Improved customer on time delivery from 92% to 99% during the 2 year period.

Materials Manager – Shelbyville, Indiana 2002 – 2003

Responsibilities and Accomplishments

• Supervised approximately 20 associates while overseeing the following areas: scheduling, shipping,

receiving and the ordering of direct and indirect materials.

• Established customer relationship which helped to Improved Chrysler delivery rating from 32% to 88% over

a six month period.

• Increased perpetual inventory accuracy for direct materials from 60% to 91%.

• Directed a Mapics ERP software implementation which integrated the facility’s inventory, accounting,

scheduling and shipping processes.

Oxford Automotive

Manufacturing Systems Leader – North America and Europe 2000 – 2002

• Directed a Mapics ERP software implementation in Turin, Italy.

• Provided consulting and training to end users residing in North America and Europe. Support and

consultation included: Inventory Management, Engineering, Material Requirements Planning, Purchasing

and Electronic Data Interchange (EDI).

• Developed detailed operational procedures for all identified business processes.

• Directed and implemented the increased utilization of Inventory Management/Material Requirements Planning

for increased Inventory Accuracy and Inventory Reduction.

Industrial Engineer - Wallaceburg, Ontario 1999- 2000

• Plant Leader for Mapics ERP Implementation.

• Developed Cost Estimates for new business opportunities.

• Performed Work Measurement/Time Study to develop work standards and increase productivity in a union environment.

• Analyzed Manufacturing Flow to realize reduced material handling opportunities and cost savings.

• Implemented kanban inventory control and production scheduling system.

EDUCATION

1996 to 1999 Dalhousie University Bachelor of Industrial Engineering

1992 to 1996 Dalhousie University

Bachelor of Science (Mathematics) and

Diploma in Engineering

References available upon request.

Contact this candidate